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    #16
    OK, here's an update on the muffler.

    So far I've done about 1000kms (600 miles) on it. It's going really well except...

    ... except there is a crack running around the end of the muffler, where the shorter 'end cone' meets the 2" central exhaust pipe at the exit. :shock:

    At first I thought it was just a dodgy weld. But today I noticed that when the muffler is hot, the pipe protrudes about 0.5mm, and when it's cold it goes inside the end of the cone about 0.5mm

    In other words, the cracking is caused by the central pipe expanding at a greater rate than the external muffler sleeve.

    So, the first design improvement on future mufflers I make, will be an internal expansion joint.

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